Process Technology

Broad Base. Best Solutions.

Block Heat Exchangers

DIABON®

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SGL Group – The Carbon Company

SGL Group – The Carbon Company – is one of the world’s leading manufacturers of carbon-based products. We have a comprehensiveportfolio ranging from carbon and graphite products to carbon fibersand composites.

Our core competencies include a wide knowledge of raw materials, specialized production expertise and in-depth application andengineer ing know-how. As a result, we have built up a comprehensivetechnology and product portfolio. We operate on a global scale and are close to our customers anywhere at any time. Supported by this broad base, we offer our customers the best solutions. That is what SGL Excellence stands for.

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Our Business Line Process Technology is focused on supporting the technical processes of our globally operating customers in the chemical industry, metal manufacturing and environmental protectiontechnology. A maximum degree of know-how and expertise in corrosionprotection, a global presence and full-package systems from a singlesource: that’s what our customers need – and get from us:

Process TechnologyPerfection in Graphite and PTFE

� Long-standing experience and a high level of expertise in process technology

� Comprehensive process, material and design know-how on graphite and PTFE

� Closeness to customers: cost-effective manufacturing to internationaland local standards at our production sites in Europe, America andAsia and worldwide customer service

� A consistently high standard of quality

Our comprehensive range of products and services extends from process equipment and components made from DIABON® graphiteand POLYFLURON® virginal, paste-extruded PTFE, through LICUFLON® skived PTFE sheet-lined equipment, FLUROFLEX®

bellows, FLUROPIPE® pipe systems, FLUROSIC® silicon carbideheat exchangers and DIABON® graphite or exotic metal pumps, to the planning and assembly of complex systems.

Contents

Product Line 4

Features and Applications 5

Carbon Fiber-Reinforced Blocks 6

Block Heat Exchangers – Cylindrical Design 7

Block Heat Exchangers – Cubic Design 10

Block Heat Exchangers – Monoblock Design 12

Technical Specifications 13

Customer Service 14

Quality Management 15

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DIABON® Block Heat Exchangers Product Line

Cylindrical DIABON® graphite blocks

DIABON graphite block heat exchangers are flexi-ble in use. They are suitable for all heat exchangeand mass transfer processes involving corrosivemedia. SGL Group’s block heat exchangers areused in all branches of the organic and inorganicchemical industry.

Our range of DIABON block heat exchangers includes:

Cylindrical Block Heat Exchangers� CK� CM (new design)

Cubic Block Heat Exchangers� NEC� EC

Monoblock Heat Exchangers� KU

All our block heat exchanger series combine the following advantages:� Suitability for corrosive media on both service

and product sides, depending on the design� High thermal efficiency even with low mass

flows� Easy servicing (easy cleaning and block

replacement) � Increase of block heat exchanger transfer area

by adding block elements� Modularity

They can be used:� For cooling and heating of corrosive media� For heat exchange between two corrosive

media

� As forced and natural circulation evaporators� For full and partial condensation (extended

bottom header for phase separation on request)� For absorption with simultaneous cooling

Due to their compactness and modularityour block heat exchangers can be usedas:� Pickling line heaters� Reactor coolers� Vent condensers and sump coolers � Circulation coolers for quenchers� Preheaters for evaporators� Reboilers� Steam heaters� Condensers

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Characteristic Features and Applicationsof DIABON® Graphite

DIABON® NS1

PropertiesDIABON NS1 is an impervious,synthetic resin-impregnatedprocess equipment graphitewith a homogenous materialstructure. The maximum per-missible material temperature is 200°C.

ApplicationStandard material for the pro-duction of heat exchangers andHCl synthesis plants as well asfor all other pressure- and tempe-rature-stressed components.

DIABON® NS2

PropertiesGraphite material for superiordemands. DIABON NS2 ischaracterized by higher strength,better corrosion resistance andlower sensitivity to swelling thanDIABON NS1 graphite. Thehomogenous material structurehas small pore sizes and a uni-form pore size distribution. Themaximum permissible materialtemperature is 200°C.

ApplicationTube sheets, blocks and tubes for heat exchangers in case ofhigher mechanical stress and/orextremely corrosive media andsolvents.

Micrograph of DIABON® NS1 Micrograph of DIABON® NS2

DIABON® CT

PropertiesDIABON CT is an impervious,PTFE-impregnated processequipment graphite with a veryhomogenous material structure.The maximum material tempera-ture is 200° C. DIABON CT issuitable for oxidizing or basicenvironments and has anti-adhesive properties.

ApplicationBlocks for block heat exchang-ers, especially for stainless steelpickling and pharmaceuticalindustries.

Micrograph of DIABON® CT

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Carbon Fiber-Reinforced DIABON® Blocks for Improved Reliability

Highly pretensioned carbon fibers are wrappedaround the DIABON blocks. The high modulus ofelasticity of the carbon fiber ensures that the ten-sion on the reinforcement is retained even undersharply fluctuating load or stress surges – no fatigueis experienced.

The DIABON HF carbon fiber reinforcementdoes not impair resistance to corrosion becauseits chemical resistance is identical to that of syn-thetic resin-impregnated graphite.

Due to the carbon fiber’s negative coefficient ofthermal expansion (volume increase in diameter),the tension on the reinforcement is further increasedwhen the temperature rises. As a result, the burstingpressure and maximum leakage resistance pressureare improved at higher temperatures than roomtemperature.

The reinforcement with carbon fibers markedly im-proves the mechanical properties of graphite com-ponents. Today, many DIABON graphite heatexchangers subject to special stresses are fittedwith carbon fiber-reinforced blocks and headers.

Carbon fiber-reinforced block component

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DIABON® Block Heat Exchangers Cylindrical Design

DIABON block heat exchangers of this design consist of DIABON graphite blocks that incorpo-rate horizontal and vertical passages. The blocksare stacked on a baseplate with corrosion-resistantgaskets between each.

A steel shell fits over the block column and is boltedto the baseplate. The block column is secured by atop pressure plate bolted to the steel shell. The jointbetween the steel shell and topheader is sealed with an O-ring toallow free movement of the shell.The difference in thermal expan-sion between graphite and steelis compensated for by helicalcompression springs.

Cylindrical block heat exchanger, series CK

Base plate and bottom header,series CK

Base plate, bottom header and one block,series CK

Block column with steel shell,series CK

As a rule, the corrosive medium flows through thevertical passages of the DIABON blocks. Fluid enters the heat exchanger through a DIABON hea-der, flows through all the blocks and is collectedon the opposite side in another DIABON headerbefore leaving the equipment.

The service medium, usually in the shell space, pas-ses through the horizontal passages of the DIABONblocks. A baffle cage optimizes the flow throughthe horizontal passages on the service side.

When two corrosive fluids are involved, a suitableanti-corrosion coating or lining can be offered onthe shell side (e.g. in rubber, PTFE, special metal).

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Our Cylindrical DesignAdvantages and Design

Advantages� Monolithic blocks� 200 to 1500 mm diameter� Modular design� Outstanding corrosion

resistance of DIABON� High heat transfer efficiency � Multipass operation

Field of application� Condensers� Coolers� Heaters� Evaporators� Falling-film absorbers

Designs� Maximum pressure on prod -

uct and service side: 7 bar� Maximum material

temperature: 200°C� Number of blocks: up to 15 � Product passage diameter:

8 or 16 mm� Heat exchange area:

– CKS: 0.91 to 600 m2

– CKDS: 1 to 850 m2

– CKL: 0.72 to 500 m2

– CKDL: 1 to 660 m2

– CM: 1.1 to 171 m2

– CM: 1.1 to 246 m2

� Block material brands:– DIABON® NS1– DIABON® NS2– DIABON® NS+– DIABON® HF1– DIABON® HF2– DIABON® CT– DIABON® CT+

Cylindrical block column with baffle cage

� Seals:– PTFE – SIGRAFLEX®

� Installation options:– vertical– horizontal– tilted

� Inspections according to:– AD 2000 specification– ASME– Stoomwezen– CODAP

� Main options:– Graphite header for

gas-liquid separation– Distribution header for

falling-film absorbers– Detachable header for

in-situ cleaning of blocks– Steel shell lining (rubber,

PTFE, etc.) for processesinvolving corrosive fluids on the service side

– DURABON plate to mini -mize erosion by abrasivefluids containing solids, for instance

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Our Cylindrical DesignSeries CK / CM

Series CKSFeatures� Product passage diameter 8 mm� Suitable mostly for clean media� Suitable for evaporation and

condensation stage� Suitable for low product flows

Series CKDSFeatures� Double -row drilling on process side� Product passage diameter 8 mm� Suitable mostly for clean media� Suitable for evaporation

and condensation stage� Suitable for low product flows� Suitable for applications requiring

a large flow cross-section on the product side

Series CKLFeatures� Product passage diameter 16 mm� Suitable for contaminated media� Easy to clean� Condensation under vacuum� Reflux condensation� Falling-film absorption

Block heat exchanger, series CM

Series CKDLFeatures� Double -row drilling on

process side� Product passage diameter

16 mm� Suitable for contaminated media� Easy to clean� Suitable for applications

requiring a large flow cross-section on the product side

� Condensation under vacuum� Reflux condensation

Series CMFeatures� Modular design� Outstanding corrosion

resistance� Low weight� Carbon fiber reinforcement

is possible� Short lead time� Corrosive fluids on both sides� No external corrosion� Steel shell-free design� No risk of cross contamination

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DIABON® Block Heat Exchangers Cubic Design

Base plate and bottom header,series NEC

Base plate, bottom header and one element,series NEC

Cubic block heat exchanger,series NEC

Cubic block heat exchanger,series NEC

Field of application� Coolers� Condensers� Heaters� Interchangers

Advantages� Modular design� Outstanding corrosion resistance of DIABON� High heat transfer efficiency� Easy servicing and repair � Vertical, horizontal or tilted design� Multipassing and multiple adaptation features

(e.g. cooling water and brine)� Suitable for pharmaceutical and fine-chemical

industries� No risk of cross-contamination

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Series EC

Features� The service medium in this heat exchanger

series is distributed by machined carbon steel plates

Maximum permissible service data

Max. service pressure

Max. service temperature

Heat exchange area

Block no. / heat exchanger

Product passage diameter

Product side 5 bar

Service side 5 bar

200°C

0.5 to 259 m2

max. 12 items

10, 12, 18 and 20 mm

Product side 7 bar

Service side 7 bar

200°C

0.8 to 145 m2

max. 12 items

10 mm

EC NEC

DIABON® block heat exchanger, series NEC DIABON® block heat exchanger, series EC

Series NEC

Features� Lateral distribution chambers are machined

within the graphite block� Lateral plates are manufactured in carbon

steel

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DIABON® Block Heat Exchangers Monoblock Design

Base plate and DIABON® block,series KU

Open DIABON®

monoblock heat exchanger,series KU

DIABON® monoblock heat exchanger, series KU

Field of application� Interchanger� Heater� Cooler

Series KU

Features� Processes with low temperature differential

and/or temperature cross� Heat exchange between two corrosive fluids � Outstanding corrosion resistance of DIABON� Limited number of gaskets since it is produced

out of one single monolithic block� Very versatile design as far as the flow rates

on both sides are concerned� Rugged design

Our KU design can be used successfully betweentwo highly corrosive, pressurized media. This mono-block heat exchanger series is made from a singlemonolithic DIABON graphite block that includesintegrated baffles on the product and service sidesproduced by milling. The graphite block is sealedon four faces with PTFE-lined steel plates that arebraced together.

The heat exchange area varies from 0.5 to 110 m2.The maximum product and service pressure is up to10 bar, the maximum temperature is 200°C.

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Screen shot of an HTRI design calculation

Screen shot of an Aspen Plus design calculation

Technical Specificationsfor Block Design

The design calculations for DIABON graphite blockheat exchangers are carried out by our experiencedapplication engineers. The thermal design calcula-tions are performed with a tried and tested programdeveloped by ourselves or with the help of interna-tionally proven and recognized software such as

� Aspen Tasc+� HTRI

FEM model

HTRI software is used to optimize the geometry ofthe DIABON graphite block heat exchangers andto calculate the necessary mechanical strength.

On request, we would be pleased to assist you inthe selection of the most suitable heat exchangerfor you application and provide a free quote.

Heat and mass transfer processes are modeledusing Aspen Plus and the equipment is then designed separately.

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Individual tube testing on a shell and tube heat exchanger

Customer Servicewith a Full Package of Benefits

Our continuing partnership with customers is based on the excellentservices and system solutions we provide. These are a key part of ourcommitment.All items of SGL Group’s DIABON process equipment are qualityproducts manufactured in our own plants from high-grade materialsusing the latest technologies. If a product still failsto meet your requirements, SGL Group’s world -wide network of service centers will be on handto help. We see every problem as a fresh oppor-tunity. Give us the chance to prove it.

Spare parts and repairsSGL Group’s responsibility for its products doesn't end when customerstake delivery of DIABON equipment. In fact, we give our customerssystematic support all the time it's in use. This support is a key part ofour customer service. The long service life of our graphite equipment depends crucially onits high quality and the servicing and/or cleaning it gets when incontact with highly corrosive and contaminated media.

Visual inspection of a tube sheet

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Heat exchanger during pressure testing

As a manufacturer of carbon and graphite products, process equipmentand systems for the chemical industry and environmental protection tech-nology, SGL Group maintains a targeted quality management systemdesigned to attain and meet the product quality standards demandedby customers. Our quality management system meets the require-ments of DIN EN ISO 9001:2000 and Pressure Equipment Directive97/23/EC Annex III, Module H/H1 and has been certified by the ap-proved associations of DQS and TÜV SÜD. In process equipment con-struction, Quality Management is responsible for the testing andapproval of semi-finished graphite products, impregnating resin, cementcomponents, outsourced parts, process equipment and components.

Quality Management by Process Technology

Synthetic resin impregnation, cementing and assemblyare all subject to continuous monitoring.

Appropriate marking of the semi-finished graphite prod-ucts before and after synthetic resin impregnation, during

machining and thereafter until assembly of the completeequipment or plant provides comprehensive evidence of the

semi-finished products employed. Consequently, they meetthe traceability requirement of specification AD 2000-Merk-

blatt N2 for pressure vessels made from electrographite andhard burned carbon. The conditions for synthetic resin im-pregnation of the semi-finished graphite products and those forcementing of the components are stipulated, monitored andchecked.

Evidence of the quality characteristics of the material gradesemployed, as required by specification AD 2000-MerkblattN2, is provided in a report issued by the testing laboratoryof TÜV SÜD Industrie Service GmbH.

Process Technology

SGL CARBON GmbH

Werner-von-Siemens-Straße 1886405 Meitingen/GermanyPhone +49 8271 83-1564Fax +49 8271 83-2101pt@sglcarbon.de

www.sglcarbon.com

Process Technology Brochures

� Process Technology – We Combat Corrosion – from Process Equipment and Components to Complex Systems

� DIABON® Graphite for Engineered Process Equipment

� DIABON® Shell and Tube Heat Exchangers

� DIABON® Block Heat Exchangers

� DIABON® Plate Heat Exchangers

� DIABON® Economizers for Heat Recovery

� DIABON® and LICUFLON® Columns and Column Internals

� DIABON® Hydrogen Chloride Synthesis Plants

� DIABON® and Exotic Metal Pumps

� DIABON® Safety Disks

� Systems – Solutions for Corrosive Processes

� ECOPOR® Porous Burners

® registered trademark of SGL Group companies 01 2008/1 2NÄ Printed in Germany

The data contained herein represent the current state of our product knowledge and are intended to provide general information on our productsand their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as generalinformation that gives no guarantee of any specific properties and/or suitability of those products for any particular application. Consequently,when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, ourtechnical service will supply a profile of characteristics for your specific application requirements without delay.